So I was reattaching the garage door opener traveling mechanism after disengaging it because I left town and noticed the part that attaches to the door itself was missing one of the four bolts/screws. This is a point of high-stress during opening, so I definitely wanted to get it replaced. While up on the ladder, I also noticed one the three remaining screws was very loose. I popped it out and went off to the hardware store to get a replacement for the missing screw, which is a self-drilling sheet metal type. Turns out that was a waste of time because the missing screw had stripped out its hole. And, to make matters worse, the loose screw also was on the verge of stripping out.
I'm a bit angry at the situation. I mean, who uses sheet metal screws for such a high-stress application? This is where the door opener literally yanks the door up to get it open. And it's attached with sheet metal screws. You can see in the photo that the sheet metal itself is starting to fail, probably because of the uneven stress from only two screws doing the work of four. What a piece of junk.
So, I need to engineer a fix. The only thing I can think of - short of replacing the entire door - is
drill all four screw holes completely through the door and reattach the mechanism with proper bolts. The bolt heads would be exposed to the outside and I will have created four points of weather corrosion but with the right kind of sealant it should work. I really don't care about the aesthetics of the bolts showing. I just don't want the door to fail. Because the door is basically two aluminum sheets with some sort of insulating filler in between, I think I'll also have to install a steel backing plate on the outside to distribute the forces from the bolts over a larger area.
Unless anyone has a better idea. Here's a photo. The screw in the 9 o'clock position is the one that's essentially stripped out.
Attachment 25370